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DESIGN OF AN ABOVE GROUND SULPHURIC

ACID STORAGE TANK





Final Year Project Report

Group: 53 Batch: 2009-2010


Muhammad Anas

ME-09139
S.M Ali Asad Jafri
Mirza Noman Baig
ME-09185
ME-09322
Irfan Khan Lodhi ME-09070



Internal Advisor:



Mr. Akhlaque Ahmed
Assistant Professor
Department of Mechanical Engineering





Reference#: 53/2013

CERTIFICATE

It is to certify that the following students have completed their project Design of an above ground
Sulphuric acid tank" satisfactorily.
Group: 53 Batch: 2009-2010
Name Seat No.


Muhammad Anas

ME-09139
S.M Ali Asad Jafri
Mirza Noman Baig
ME-09185
ME-09322
Irfan Khan Lodhi ME-09070







Internal Advisor
Mr. Akhlaque Ahmed

Assistant Professor




Project Coordinator
Dr. Muhammad Shakaib
Associate Professor

DEPARTMENT OF MECHANICAL ENGINEERING
NED UNIVERSITY OF ENGINEERING AND TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
NED UNIVERSITY OF ENGINEERING AND TECHNOLOGY
ii
ACKNOWLEDGEMENTS


The special thank goes to our helpful teacher, Mr. Akhlaque Ahmed -Assistant Professor
Mechanical Department (NEDUET).The supervision and support that he gave truly help
the progression and smoothness of the Storage Tank Design. The co-operation is much
indeed appreciated.

Our grateful thanks also go to Mr. Ahmed Mustafa Manager at Engro Polymer . A big
contribution and hard worked from him during the project is very great indeed. All practical
concepts and knowledge during the project would be nothing without the enthusiasm and
imagination from him. Besides, this project makes us realized the value of codes & standards
in designing of mechanical elements, which challenges us every minute. Not forget, great
appreciation go to the rest of classmates that help us from time to time during the project. The
whole project really brought us together to appreciate the true value of friendship and respect
of each other.

Last but not least we would like to thank Mr. Ahmed Mustafa Manager at Engro
Polymer for providing free demo version of Etank2000 that truly helps in verification of our
results.
Finally, Special thanks also to Dr. Muhammad Shakaib Project Coordinator, that have
encouraged, support and help us in completing this course successfully.


iii

ABSTRACT


This project represents the designing of storage tank. It includes sufficient information and
knowledge on how a storage tank is designed and which parameters are considered while
designing a storage tank according to codes and standard.

Storage tanks have been widely used in many industrial particularly in the oil refinery and
petrochemical industry which are to store a multitude of different product with Sulphuric acid
as one of it.

There are various industrial code and standard available for the basic requirement for tank
design and construction. Design and safety concern has been a great concern for the
increasing case of fire and explosion due the tank failure.

Although every effort has been made to obtain the most accurate solutions, it is the nature of
engineering that certain simplifying assumption is made. Solutions achieved should be
viewed in this light, and where judgment is required, they should be made with due
concentration.

This project describes different classification of storage tank followed by the description of
major components of a storage tank. The calculations are made as per API 650 code.



iv

TABLE OF CONTENTS

Contents Page No
Acknowledgements ii
Abstract iii
List of figures x
List of Tables xii

2.2 Types of Storage Tanks...5
2.2.1 Classification Based on Internal Pressure..6
2.2.1.1 Atmospheric Tanks..6
2.2.1.2 Low Pressure Tanks6
2.2.1.3 High Pressure Tanks6
2.2.2 Classification Based on Roof Type8

2.2.2.1 Fixed Roof Tanks...8
2.2.2.1.1 Cone Roof Tanks10
2.2.2.1.2 Umbrella Roof Tanks.11
2.2.2.1.3 Dome Roof Tanks..11
2.2.2.2 Floating Roof Tanks...12.
2.2.2.2.1 Internal Floating Roof ....12
2.2.2.2.2 External Floating Roof. 13
2.3 Process Description and Requirements....14
2.4 Design Factors considered in the Design of Storage Tanks....15
2.4.1 Metal Temperature...15
2.4.2 Pressure ...15
2.4.3 Specific Gravity.16
2.4.4 Corrosion Allowance..17
2.4.5 Other Loads....18
2.5 Mechanical Design.....19
2.6 Mechanical Design Considerations....20
2.7 Tank Assembly...22
v

2.7.1 Shell Attachments...22
2.7.1.1 Permanent Attachments..22
2.7.1.2 Temporary Attachments.....22
2.7.2 Tank Venting..22
2.7.3 Wind Girder....23
2.7.3.1 Secondary Wind Girder..23
2.7.4 Clean-out Doors.....23
2.7.5 Stairways and Handrails.24
2.7.6 Drainage arrangement....24
2.7.7 Nozzles...25.
2.7.8 Manholes....25
2.7.9 Anchor Bolts..26

3. INTRODUCTION TO API...27
3.1 Introduction..27
3.2 Standards and certification...27
3.3 API 650 (Welded steel tanks for oil storage)28
3.3.1 Scope.....29
3.3.2 Materials...29
3.3.3. Design...30
3.3.3.1 Welded Joints...30
3.3.3.1.1 Double-welded butt joint..30
3.3.3.1.2 Single-welded butt joint with backing..30
3.3.3.1.3 Double-welded lap joint .....30
3.3.3.1.4 Single-welded lap joint....30
3.3.3.1.5 Butt-weld. ..30
3.3.3.1.6 Fillet weld..30.
3.3.3.1.7 Full-fillet weld...30
3.3.3.1.8 Tack weld .30
3.3.3.2 Weld Size....30

3.3.3.3 Restrictions on Joints...30
vi


3.3.3.4 Typical Joints.........31

3.3.3.4.1 Vertical Shell Joints31
3.3.3.4.2 Horizontal Shell Joints31
3.3.3.4.3 Lap-Welded Bottom Joints.31
3.3.3.4.4 Butt-Welded Bottom Joints....31
3.3.3.4.5 Bottom Annular-Plate Joints...31
3.3.3.4.6 Shell-to-Bottom Fillet Welds..31
3.3.3.4.7 Wind Girder Joints..31
3.3.3.4.8 Roof and Top-Angle Joints.32
3.3.3.5 Loads..32

3.3.3.5.1 Dead load (D
L
) ...32
3.3.3.5.2 Stored liquid (F).....32
3.3.3.5.3 Hydrostatic test (H
t
)...32
3.3.3.5.4 Minimum roof live load (L
r
).32
3.3.3.5.5 Snow (S)................... 32
3.3.3.5.6 Wind (W) .....32
3.3.3.5.7 Design internal pressure (P
i
) 32
3.3.3.5.8 Design external pressure (P
e
)32
3.3.3.5.9 External Pressure......32
3.3.4 Marking.....33

3.3.4.1 Nameplates...33


4. TANK DESIGN34
4.1 Introduction...34

4.2 Shell Design...34

4.3 Calculating Shell Thickness...35

vii

4.3.1 One-Foot Method...35

4.3.2 Variable Design Point Method...35

4.4 Shell Design by one foot method36
4.4.1 Longitudinal Stress..37

4.4.2 Circumferential Stress ....37

4.4.3 Longitudinal Stress versus Circumferential Stress..38

4.4.4 Circumferential Stress Thickness Equation and 1-Foot Method 39

4.5 Top Stiffener and Intermediate Wind Girder Design..39
4.5.1 Top Stiffener/ Top Wind Girder..39

4.5.2 Intermediate Wind Girder40

4.6 Bottom Plate Design.43

4.7 Roof Design..44

4.8 Overturning Stability against Wind Load.45.

4.9 Seismic Design..47

4.9.1 Overturning Stability against seismic load...47

4.10 Anchorage requirement.48

.
5. 0 DESIGN CALCULATIONS50

5.1 Material Selection .50

5.2 Design Specifications.51

5.3 Basic Calculation....52

5.4 Shell Design53

5.5 Bottom Plate Design .......56

5.6 Annular Plate Design...56

5.7 Intermediate Wind Girder58

5.8 Roof Design (Supported Conical Roof )..61

viii

5.8.1 Roof Plate Design.61

5.9 RAFTER DESIGN ..............63
5.10 COLUMN DESIGN.64
5.11 Tank Overturning Stability...68
5.12.1 RESISTANCE TO OVERTURNING (per API-650 5.11.2) .. 71
5.12.2 Stability of Tank against Seismic Load .... 73
5.12.3 SEISMIC VARIABLES .74
5.12.4 STRUCTURAL PERIOD OF VIBRATION..76

6.0 RESISTANCE TO DESIGN LOAD .77

6.1 EFFECTIVE WEIGHT OF PRODUCT .....77
6.1.1 DESIGN LOADS 77
6.2.1 CENTER OF ACTION FOR EFFECTIVE LATERAL FORCES ..78
6.2.2 CENTER OF ACTION for RINGWALL OVERTURNING MOMENT...78
6.2.3 CENTER OF ACTION for SLAB OVERTURNING MOMENT .79
6.2.4 Dynamic Liquid Hoop Forces .79
6.2.5 Overturning Moment ...80
6.2.6 RESISTANCE TO DESIGN LOADS.....80
6.3 ANCHOR BOLT DESIGN..83
6.4 CAPACITIES and WEIGHTS .....87

7.0 DEVELOPMENT OF STORAGE TANK DESIGN SOFTWARE &
VERIFICATION OF RESULTS USING ETANK 2000.93
7.1 Overview....93

7.2 Design Capabilities.93
7.3 Key Features 93
7.4 Application Areas.93
ix

7.5 Visual Basic Programming for Shell Design.94
7.6 VERIFICATION OF RESULTS..101

CONCLUSION..103
REFERENCES...104

APPENDIX105

Appendix C Shell Design....107

Appendix D Bottom and annular Plate Design...110

Appendix E Intermediate wind girder ...112

Appendix F Roof Design114

Appendix G Tank overturning stability..117















x

LIST OF FIGURES
Figure 1 Types of Tank ............................................................................................. 4
Figure 2 Tanks on the basis of internal pressure ..................................................... 7
Figure 3 Fixed roof tank ........................................................................................... 8
Figure 4 Fixed roof tank ........................................................................................... 9
Figure 5 Steel tank with cone roof .......................................................................... 10
Figure 6 Cone roof tank with column supports ...................................................... 10
Figure 7 Umbrella Roof Tank11
Figure 8 Dome roof tank ........................................................................................ 11
Figure 9 Internal floating roof tank........................................................................ 12
Figure 10 External floating roof tank ....................................................................... 13
Figure 11 Storage tank capacities and levels shell .................................................. 14
Figure 12 Hydrostatic pressure in a storage tank .................................................... 16
Figure 13 Corrosion allowance in a tank shell ........................................................ 17
Figure 14 Wind and earthquake loads ..................................................................... 18
Figure 15 Tank exploding ......................................................................................... 20
Figure 16 Loading diagram on a tank shell ............................................................. 21
Figure 17 Tank Venting....22
Figure 18 Wind Girder placement on shell.. 23
Figure 19 Cleanout Door...23
Figure 20 Stairways and handrails.....24
Figure 21 Nozzle....25
Figure 22 Manholes......25
Figure 23 Anchor Bolts........26
Figure 24 Name Plates of storage tanks....33
Figure 25 Diagramatic variation of stress in a shell...34
Figure 26 Thickeness of tank shell courses...35
Figure 27 Longitudinal forces acting on thin cylinder....37
Figure 28 Circumferential forces acting on thin cylinder .........38
Figure 29 Stiffener rings.........39
Figure 30 Wind girders.41
Figure 31 Transformed shell and intermediate wind girder..42
Figure 32 Bottom Layout for tank.......43
Figure 33 Cross joints in bottom plates.............44
xi

Figure 34 Overturning moment against wind load...45
Figure 35 Shell out of roundness caused by wind.45
Figure 36 Roof Segments.......62
Figure 37 Compression ring at shell to roof joint.64
Figure 38 Selected Plate Size76
Figure 39 Surface development of shell ....77
Figure 40 Construction of upper shell course- inside tank.....78
Figure 41 Construction of upper shell course- outside tank ..78
Figure 42 Bottom plate arrangement on foundation80
Figure 43 Arrangement of bottom plates81
Figure 44 3D model of storage tank.. .83.
Figure 45 3D model of storage tank ....84
Figure 46 Arrangement of stiffener at roof.85
Figure 47 Snapshot of software87.
Figure 48 Design report showing hydroststic and design thickness..87
Figure 49 Message box indicating compeltion of calcuklations..93
Figure 50 Output Results..94
Figure 51 Verification of results thriugh E-Tank.95














xii

LIST OF TABLES

Table 1: Pepsi can and storage tank comparison table..19
Table 2: Anchorage ratio criteria [API 650,2007]..48
Table 3: BOQ for shell arrangement79
Table 4: BOQ for bottom plate arrangement..82















1
CHAPTER 1: INTRODUCTION


1.1 Rationale

Storage tanks have been widely used over the world in many industries. They are designed,
fabricated and tested to code and standard. There are a variety of codes and standards stating
the similar common minimum requirements and some additional requirements from company
standards or specifications.

Engineer or tank designer who do the preliminary and detail design are normally not familiar
or not exposed to the actual site condition. Their designs are basically based on the code and
standard requirements and basic theory from reference book. Some would only rely on the
commercial software for the basic design, they have limited knowledge on the actual tank
operation which limit them on cost effectiveness and even safety detail design.

There is limited procedure and rules in design the fixed and floating roof tanks. These had
resulted lots of roof failure in the industry. Hence industry, tank owner and also the tank
designer or engineer need to have a simple rules and formula to ensure the roof is adequately
designed and strong enough for the various loading during operation.

Beside of the procedures and rules, understanding of the stresses behave in the tank material
is essential for a complete safe design.

Hence it is essential for the engineers or tank designer to know how and what effects each
inter discipline design would have on ones tank that affected the tank integrity, and taking all
these consideration into his design.


1.2 Project Goal

1.2.1Project Aim

The aim of this project is to follow basic rules and procedures, highlighting the concerns in
designing of a fixed roof tank.

1.2.2Project Objective

The main objective of this project is To design an above ground Suphuric acid storage tank.








2

1.3 Project Methodology

1.3.1 Literature Review

Literature review is conducted to study the basic design and requirement of the fixed roof
storage tank in the storage tank design code (API 650 Welded Steel Tanks for Oil Storage).

1.3.2Design Approach

Upon completion of the literature review, design approach is then developed. The storage
tank design consists of two major designs, that is (1) the shell design analysis and (2) the roof
design.

In the shell design analysis, shell stress design will be performed taking into consideration of
all the considerably loading including hydrostatic pressure, wind loading and seismic loading.

In the roof design, it consists of two sections, that is (1) roof stress design and the (2) roof
fitting and accessories design.



1.4 Perspective view on Standards and Codes

Industries that require the storage of flammable and combustible liquids face a complex array
of codes and standards with which they must comply. Besides adhering to environmental
regulations, underground and aboveground tank systems must be sited and operated in
accordance with local building and fire codes.

1.4.1 What is a standard?

A standard is a series of requirements that tell you how to do something. A standard tends not
to have any enforcement requirements. A standard becomes an enforceable document when it
is adopted by reference in a code.

1.4.2 What is a code?

A code is a set of regulations that tells you when to do something. A code will have
requirements specifying the administration and enforcement of the document.

1.4.3How Does a Code or Standard Become Enforceable?
A code or standard becomes enforceable when it is adopted by reference through local, state,
or federal government legislative process, such as an ordinance, statute, or bill. The law must
adopt a specific edition (year of publication) of a code or standard, and may include
amendments to specific portions of the code or standard being adopted.
3

CHAPTER 2: LITERATURE REVIEW

2.1 Introduction

Storage tanks have been widely used in many industrial established particularly in the
processing plant such as oil refinery and petrochemical industry. They are used to store a
multitude of different products. They come in a range of sizes from small to truly gigantic,
product stored range from raw material to finished products, from gases to liquids, solid and
mixture thereof.

Liquids and vapors in the petroleum industry, usually called petroleum liquids or vapors
generally are mixtures of hydrocarbons having dissimilar true vapor pressures. Examples
would include jet fuel diesel, gasoline and crude oil.

Liquidsandvaporsinthechemicalindustry,usuallycalledvolatileorganicliquidsand vapor,
are composed of pure chemicals or mixtures of chemicals with similar true vapor
pressures. Examples would include benzene, styrene, and alcohols.

There are a wide variety of storage tanks, they can be constructed above ground, in ground
and below ground. In shape, they can be in vertical cylindrical, horizontal cylindrical,
spherical or rectangular form, but vertical cylindrical are the most usual used.

In a vertical cylindrical storage tank, it is further broken down into various types, including
the open top tank, fixed roof tank, external floating roof and internal floating roof tank.

The type of storage tank used for specified product is principally determined by safety and
environmental requirement. Operation cost and cost effectiveness are the main factors in
selecting the type of storage tank.

.











.






4

2.2 Types of Storage Tanks



Figure 1Types of storage tank











Types Of Storage
Tanks
Based On Internal
Pressure
Atmospheric Tanks
Low Pressure Tanks
High Pressure Tanks
Based On Roof type
Fixed Roof Tanks
Cone Roof
Umbrella Roof
Dome Roof
Floating Roof Tanks
Internal Floating
Roof
External Floating
Roof
5

2.2.1 Classification Based on Internal Pressure

In the case the internal pressure reacts on the tank during storage, it is possible to classify the
tanks based on this level of pressure. This pressure effect depends directly of the size of the
tank. The larger the tank, the more severe effect of pressure is on the structure. This
classification is commonly employed by codes, standards and regulations all over the world.

2.2.1.1 Atmospheric Tanks

These tanks are the most common. Although they are called atmospheric, they are usually
operated at internal pressure slightly above atmospheric pressure. The fire codes define an
atmospheric tank as operating from atmospheric up to 3.5 kN/m
2
above atmospheric
pressure.


2.2.1.2 Low-Pressure Tanks

Within the context of tanks, low pressure mean that tanks are designed for a pressure higher
than atmospheric tanks. Tanks of this type are designed to operate from atmospheric pressure
up to about 100 kN/m
2
.


2.2.1.3 Pressure Vessels (High-Pressure Tanks)
Since high-pressure tanks are really pressure vessels, the term high-pressure tank is not
frequently used; instead they are called only vessels. Because these kinds of tanks are usually
built underground, they are treated separately from other tanks by all codes, standards, and
regulations.
6




Figure 2Tanks on the basis of Internal Pressure


7

2.2.2 Classification based on Roof Type

2.2.2.1 Fixed Roof Tanks

Fixed Roof Tanks can be divided into cone roof, umbrella roof and dome roof types. They
can be self-supported or rafter/ trusses supported depending on the size.

Of currently used tank designs, the fixed-roof tank is the least expensive to construct and is
generally considered the minimum acceptable equipment for storing VOL's (volatile organic
liquids).A typical fixed-roof tank consists of a cylindrical steel shell with a cone- or dome-
shaped roof that is permanently affixed to the tank shell. Most recently built tanks are of all-
welded construction and are designed to be both liquid-and vapor-tight.

For fixed-roof tanks, the nominal capacity is the geometric volume from the bottom of the
tank up to the cur bangle, which is a metallic angle that is welded along the periphery at the
top of the cylindrical portion of the tank.





Figure3FixedRoofTank




8











Figure4FixedRoofTank





9

2.2.2.1.1Cone Roof Tanks
Cone-roof tanks have also cylindrical shells in the lower part. These are the most widely
used tanks for storage of relatively large quantities of fluid. They have a vertical axis of
symmetry; the bottom is usually flat land the top is made in the form of shallow cone. They
are economical to build and the economy supports a number of contractors capable of
building them. Cone-roof tanks typically have roof rafters and support columns excepting
very small-diameters tanks.







Figure5Steel Tank with cone-roof








Figure 6Cone-rooftankwithcolumnsupports
10

2.2.2.1.2 Umbrella-Roof Tanks

They are very similar to cone-roof tanks, but there of looks like an umbrella. They are
usually constructed with diameters not much larger than 20 m. Another difference is that
the umbrella-roof does not have to be supported by columns to the bottom of the tank, so
that they can be a self-supporting structure.


Figure7UmbrellaRoofTank

2.2.2.1.3 Dome-Roof Tanks

This type has almost the same shape of the umbrella type except that the dome approximate
a spherical surface more closely than these gentled sections of an umbrella-roof. There are
several ways to fabricate such tanks. One of the known as the tank airlift method, "in which
the roof and the upper course of shell are fabricated first, then lifted by air that is blown in to
the tanks as the remaining lower courses of steel shell are welded into place.



Figure8DomeRoofTank
11

2.2.2.2 Floating Roof Tanks

Floating roof tanks is which the roof floats directly on top of the product.
There are 2 types of floating roof:

2.2.2.2.1 Internal Floating Roof

Internal floating roof tank is the one in which the roof floats on the product in a fixed roof
tank.






Figure9InternalFloatingRoof Tank


Peripheral roof vents Fixed-roof center vent
Fixed roof
column
supported

Tank shell
Gage head
Fixed roof
Supported column
Deck drain
Access hatch
Deck leg
Ladder
Vacuum breaker
Sample port
Rim seal


12

2.2.2.2.2External Floating Roof

External floating roof tank is the one in which the roof floats on the product in an open tank
and the roof is open to atmosphere.






Figure10ExternalFloatingRoofTank









13

2.3 Process Description and Requirements

Capacity determination is the one of the first steps in designing the tank. Only after the
capacity is known, the tank can be sized up. The definition of the maximum capacity can be
explained easily in figure below.






Figure 11 Storage Tank Capacities and Levels shell



The maximum or total capacity is the sum of the inactive capacity (minimum operating
volume remaining volume in tank), actual or net-working capacity and the-overfill protecting
capacity.
The net-working capacity is the volume of available product under normal operating
conditions, which is between the low liquid level (LLL) and the high liquid level (HLL).




14

2.4 Design Factors that are considered in the Mechanical Design of Storage
Tanks

This section discusses the primary factors that are considered in the mechanical design of
storage tanks. These factors are as follows:

1. Metal temperature

2. Pressure

3. Specific gravity of the stored liquid

4. Corrosion allowance

5. Other loads



2.4.1 Metal Temperature

The metal temperature of storage tank components is determined by the operating
requirements of the stored liquid, and by the ambient temperature at the tank location.
The operating requirements and operating conditions of the stored liquid are
determined by process engineers. The mechanical design of storage tank components
must consider both the highest and the lowest temperatures to which the tank can be
exposed.

The maximum operating temperature determines the allowable stress that is used for
the mechanical design of storage tank components. The allowable stress of each
specific material is constant for all temperatures up to 93C (200F); however, the
allowable stress of each material decreases for temperatures that are above 93C
(200F). API-650 Appendix M contains additional design criteria that must be
followed for tanks that have maximum operating temperatures over 93C (200F).
The tank could experience a permanent deformation or a ductile fracture if the design
requirements of API-650 Appendix M are not followed.


2.4.2 Pressure

The internal pressure at which a storage tank will operate determines which API
standard is to be used for the mechanical design of the tank and its associated
components. API-650, Welded Steel Tanks for Oil Storage, is the design standard for
tanks that operate at internal pressures approximating atmospheric pressure. API-650
may also be used for tanks that operate at internal pressures up to 17 kpa; however,
additional design requirements that are contained in API-650 Appendix F must be
followed if the internal pressure exceeds atmospheric pressure.



15

2.4.3 Specific Gravity of Stored Liquid

The specific gravity of the liquid that is being stored, (G), in conjunction with the
depth of the liquid determines the hydrostatic pressure of the liquid. The total
hydrostatic pressure at a given elevation in a tank must be considered in determining
the required thickness of the tank shell.




Figure 12 Hydrostatic Pressure in a Storage Tank


Storage tanks must be designed for the specific gravity of water (1.0), because the
tanks are filled with water for testing purposes after they are constructed. If the
specific gravity of the liquid that is to be stored exceeds 1.0 (water), the tank must be
designed for the higher specific gravity.

The required shell thickness is directly proportional to the specific gravity of the
stored liquid. If the specific gravity is not correctly specified, the calculated shell
thickness will be incorrect. In extreme cases, the shell can become permanently
deformed if it is too thin, and a ductile fracture may occur.

It may be desirable for operational reasons to change the liquid that is being stored
after the tank has been in service for some period of time. In situations where the
stored liquid is changed, the tank must be evaluated based on the specific gravity of
the new liquid.




16

2.4.4 Corrosion Allowance

The components of a storage tank may lose metal due to corrosion that is caused by
the stored liquid. To compensate for this metal loss, a "corrosion allowance" (CA)
may be added to the metal thickness that is required for strength. This "corrosion
allowance" offsets the expected deterioration of the tank components while they are in
service. When needed, the corrosion allowance is typically added to the calculated
required thicknesses of the shell, internal components, and structural members that
may be used to support a fixed roof. A corrosion allowance is typically not added to
the required thicknesses of the roof itself or the bottom.



Figure 13 Corrosion Allowance in Tank Shell
Where

t = Minimum required shell thickness
T = Total required shell thickness
CA = Corrosion allowance



17



2.4.5 Other Loads

The mechanical design of a storage tank must also consider loads other than pressure.
These other loads include wind and earthquake, loads that are imposed by connected
piping systems (and other attachments) on nozzles, and rainwater accumulation on the
roof of tanks.






Figure 14Wind and Earthquake Loads



Where

Fw= Base shear force due to wind
M = Overturning moment due to wind or earthquake













18



2.5 Mechanical Design

Stress design and analysis of the storage tank is the greatest concern to engineer as it provides
the basic for the tank stability and integrity.

The basic stress analyses to be taken care in tank design are as follow:

Tank shell wall due to internal and external loading
Bottom plate/ Tank flooring

Storage tanks always look big and strong, and there are also often being referred as tin can.
Some simple comparison in term of their sizes and strength is made here.





Table 1 Pepsi Can and Storage Tank Comparison Table


From the Table 1, it can be seen found the tank ratio (t/D) is 4 times less than the typical bean
can which show that how relatively flimsy the shell of the tank it would be if it is subjected
to partial vacuum. Figure 19 shows tank exploding due to vacuum loading.


19


Figure 15Tank Exploding

2.6 Mechanical Design Consideration

The principal factors in determine the shell thickness is the loads, the primary loading to
determine the basic shell thickness is as follow:

The internal loading due to the head of liquid
The pressure in the vapor space

Other external loading shall be taken into consideration are:

External pressure-Vacuum condition
Wind loading
Seismic Loading
Localized loads resulting from nozzles, attachments, ladder/ stair and platform etc.






20



Figure 16Loading Diagram on a Tank Shell

The internal pressure exerted on the tank shell is the product liquid head; the pressure is at the
highest at the tank shell bottom and decreases linearly along its height. External loading of
wind and seismic act on the tank shell and create an overturning moment about the shell to
bottom joint, this result in the uplift reaction of the tank and affected the tank stability.

The various stresses to which the shell of a tank is subjected are:


Hoop tension
This is caused by the head of product in the tank, together with any over pressure in the roof
space of a fixed roof tank.

Axial compression
This comes from the tank self-weight, internal vacuum, wind and seismic loading acting on
the shell which causes an overturning effect.

Vertical bending
This is due to the expansion of shell under normal service loading.




21

2.7 TANK ASSEMBLY

2.7.1 Shell Attachments

2.7.1.1 Permanent Attachments

Permanent attachments are items welded to the shell that will remain while the tank is in its
intended service. These include items such as wind girders, stairs, gauging systems, davits,
walkways, tank anchors, supports for internal items such as heating coils and other piping
supports, ladders, floating roof supports welded to the shell, exterior piping supports,
grounding clips, insulation rings, and electrical conduit and fixtures. Items installed above the
maximum liquid level of the tank are not permanent attachments.
2.7.1.2 Temporary Attachments

Temporary attachments are items welded to the shell that will be removed prior to the tank
being commissioned into its intended service. These include items such as alignment clips,
fitting equipment, stabilizers, and lifting lugs.

2.7.2 Tank Venting

Suitable vents shall be provided to prevent overstressing of the roof deck or seal membrane.
Vents, bleeder valves, or other suitable means shall be adequate to evacuate air and gases
from underneath the roof during initial filling Tanks designed in accordance with this
standard and having a fixed roof shall be vented for both normal conditions (resulting from
operational requirements and atmospheric changes) and emergency conditions (resulting
from exposure to an external fire). Normal venting shall be adequate to prevent internal or
external pressure from exceeding the corresponding tank design pressures. Emergency
venting requirements are satisfied if the tank is equipped with a weak roof-to-shell
attachment (frangible joint).

Figure 17 Tank Venting

22

2.7.3 Wind Girder

Tank shall be provided with stiffening rings to maintain roundness when the tank is subjected
to wind loads. The stiffening rings shall be located at or near the top of the top course,
preferably on the outside of the tank shell. Stiffening rings may be made of structural
sections, formed plate sections, sections built up by welding. The outer periphery of
stiffening rings may be circular or polygonal Rings that may trap liquid shall provided with
adequate drain holes.

Figure 18 Wind girder placement on shell
2.7.3.1 Secondary wind girders

Tank may require secondary rings to maintain roundness over the full height of the tank shell
under wind and/or vacuum conditions. There are basically, additional stiffening rings.
Continuous welding (full penetration butt welds) shall be used for all connections of the
secondary wind girders.

2.7.4 Clean-out doors

If required for tanks made of carbon steel, clean out doors shall be designed and fabricated.
This is more for sludge removal and to allow entry of a conveyor belt, if required.

Figure 19 Clean-out doors
23

2.7.5 Stairways and handrails

Vertical tanks should be provided with spiral stairways. An exception may be made for
groups of tanks of less than 12.5 m diameter sited close together and connected by walkways
at roof level. In such groups, two tanks at opposite ends of each group shall be provided with
stairways, so that each tank in that group will then have at least two escape routes from the
roof.
Handrails shall be provided at the edge of the roof for full circumference of all fixed roof
tanks and to the center of the roof on all tanks exceeding 12.5 m diameter. Handrails shall be
provided on the outside of all spiral stairways. For open top tanks, the inside of the staircases
shall also be provided with a handrail in the immediate vicinity of the top landing. Handrails
shall be provided on both sides of all walkways between tanks. Stairways shall be provided
with the specified lighting facilities.

Figure 20Stairways and handrails

2.7.6 Drainage arrangement Water draw (Center drains or side drains)

In operation, tank bottoms should normally slope down towards the center and be fitted with
center sumps.
Large tanks (>50 m diameter) may also be provided with additional side drain sumps, the
nozzles of which may be blinded off after the water test.
However, for products with temperature exceeding 100, the tank bottom slope up towards
the centre in order to prevent corrosion caused by rain water penetrating under the bottom.








24

2.7.7Nozzle

When considering the nozzle, one might think that it has to do something with change in
velocity and pressure which is the application of Bernoullis equation and continuity equation
as well. In storage tanks, the nozzle is nothing but just an opening through which either the
fluid can enter or leave the storage tank.

Figure 21 Nozzle

2.7.8Manholes

Manholes are nothing but big nozzles of sizes more than 16 inch .Usually the pipe section
used for manholes will be fabricated pipe from plate. Therefore, for vessels with joint
efficiency 1, the long seem weld is category A butt, and hence calls for 100% radiography
prior to fit up of the circumferential joint between the flange and the neck. For manholes with
fabricated neck, the reinforcement pad is essential and will be provided as per design. In case
there is any practical difficulty and placement of reinforcement pad prior to the welding
manhole to the shell, it can be inserted into halves provided there are at least two tapped
telltale holes on both halves of the pad. A part from these, manufactures of manhole is the
same as that of the nozzle.

Figure 22Manholes
25

2.7.9Anchor bolts

An anchor bolt is used to attach objects or structures to concrete. There are many types of
anchor bolts, consisting of designs that are mostly propriety to the manufacturing companies.
All consist of a threaded end, to which a nut and washer can be attached for the external load.
Anchor bolts are extensively used on all types of projects, from standard building to dams
and nuclear power plants.
The simplest anchor bolt is a cast-in-place anchor. Most designs consist of standard bolt with
a hexagonal head , which is cast in the wet concrete before it sets .There are other designs,
some consisting of a bent bolt with a hook on the end, or some other sort of bending.

Figure 23 Anchor bolts












26

CHAPTER 3: INTRODUCTION TO API STANDARDS


3.1 INTRODUCTION
American Petroleum Institute (API) Standards 650, 653 and 620 are the primary industry
standards by which most aboveground welded storage tanks are designed, constructed and
maintained. These standards address both newly constructed and existing aboveground
storage tanks used in the petroleum, petrochemical and chemical industries. API Standards
650, 653, 620, and some related Recommended Practices that have been made over the years
or are being developed to improve the standards with respect to leak detection and spill
prevention. API and other standards and practices that should be followed to reduce the risk
of spills and leaks. API has published standards for the construction of aboveground storage
tanks since the mid- 1930s. API Standards for aboveground storage tanks designed for
atmospheric pressures, up to a maximum of 2.5 psig. API Standard 620 is applicable to tanks
and vessels designed for low-pressure storage, ranging from about 2.5 psig to 15 psig.
The First Edition of API 650 was published in 1961, but its predecessor, API 12C, had been
in use since 1936, when welding began to replace riveting as the preferred construction
method. Both API 12C and API 650 address only newly constructed tanks. It was not until
the late 1980s that API began development of a new standard to address specific
maintenance and inspection issues for existing aboveground storage tanks. This standard is
API 653, Tank Inspection, Repair, Alteration and Reconstruction. Since the publication of
API Standard 653 in 1991, the tank inspection, repair, alteration and reconstruction methods
prescribed therein have - when properly applied significantly improved the safety and
reliability of existing tanks. This standard and other API standards are continuously being
improved to incorporate new technology and to reflect the actual experiences of owners and
operators of aboveground storage tanks.

3.2Standards and Certification
The publications, technical standards, and online products are designed, according to API
itself, to help users improve the efficiency and cost-effectiveness of their operations, comply
with legislative and regulatory requirements, and safeguard health, ensure safety, and
(perhaps most controversially) "protect the environment". Each publication is overseen by a
committee of industry professionals, mostly member company engineers.
These technical standards tend to be uncontroversial. For example, API 610 is the
specification for centrifugal pumps, API 675 is the specification for controlled volume
positive displacement pumps, both packed-plunger and diaphragm types are included.
Diaphragm pumps that use direct mechanical actuation are excluded. API 677 is the standard
for gear units and API 682 governs mechanical seals.

27



API provides vessel codes and standards for the design and fabrication of pressure vessels
that help safeguard the lives of people and environments all over the world.
API also defines and drafts standards for measurement for manufactured products such as:
Precision thread gauges
Plain plug and ring gauges
Thread measuring systems
Metrology and industrial supplies
Measuring instruments
Custom gauges
Precision machining and grinding
3.3 API 650 (WELDED STEEL TANKS FOR OIL STORAGE)

API 650 covers material, design, fabrication, erection and testing requirements for
aboveground, vertical, cylindrical, closed and open-top, welded steel storage tanks in various
sizes and capacities. This standard applies to tanks with internal pressures approximating
atmospheric pressure, but ranging as high as 2.5 psig. This standard applies to newly
constructed tanks before they have been placed in service.
General contents are:
1. Scope
2. Materials
3. Design
4. Fabrication.
5. Erection
6. Methods Of Inspecting Joints
7. Welding Procedure And Welder Qualifications
8. Marking






28

3.3.1 Scope
This standard covers material design, fabrication, erection, and testing requirements
for vertical, cylindrical, aboveground, closed- and open-top, welded steel storage
tanks in various sizes and capacities.

Internal pressures approximating atmospheric pressure (internal pressures not
exceeding the weight of the roof plates), but a higher internal pressure is permitted
when additional requirements are met.

This standard applies only to tanks whose entire bottom is uniformly supported and
to tanks in no refrigerated service that have a maximum design temperature of 93C.

This standard is designed to provide the petroleum industry with tanks of adequate
safety and reasonable economy.

This standard does not present or establish a fixed series of allowable tank sizes;
instead, it is intended to permit the purchaser to select whatever size tank may best
meet his needs.

This standard has requirements given in two alternate systems of units, that is SI
Units and US Customary Units. System can be choose by the mutual agreement
between manufacturer and purchaser but the condition is that units must be
consistent.

The appendices of this standard provide a number of design options requiring
decisions by the purchaser, standard requirements, recommendations, and
information that supplements the basic standard.

An appendix becomes a requirement only when the purchaser specifies an option
covered by that appendix.


3.3.2Materials
Materials used in the construction of tanks shall conform to the specifications listed
in this standard.

Conditions of usage of material

i. Approved by the purchaser.

ii. Material should certify to meet all of the requirements of a material
specification listed in this standard.

New or unused plates should be completely identified by records.



29

Materials of construction are used that are certified to two or more material
specifications.

Plates for shells, roofs and bottoms may be ordered on an edge thickness basis or on
a weight(kg/m2 or lb/ft2)

Shell plates are limited to a max thickness of 45mm (1.75in).

Plates used as flanges may be thicker than 45mm (1.75in).

3.3.3Design

3.3.3.1 Welded Joints

3.3.3.1.1 Double-welded butt joint :A joint between two abutting parts lying in
approximately the same plane that is welded from both sides.

3.3.3.1.2 Single-welded butt joint with backing :A joint between two abutting parts lying in
approximately the same plane that is welded from one side only with the use of a strip bar or
another suitable backing material.
3.3.3.1.3 Double-welded lap joint: A joint between two overlapping members in which the
overlapped edges of both members are welded with fillet welds.
3.3.3.1.4 Single-welded lap joint: A joint between two overlapping members in which the
overlapped edge of one member is welded with a fillet weld.
3.3.3.1.5 Butt-weld: A weld placed in a groove between two abutting members. Grooves
may be square, V-shaped (single or double), or U-shaped (single or double), or they may be
either single or double beveled.
3.3.3.1.6 Fillet weld: A weld of approximately triangular cross section that joins two surfaces
at approximately right angles, as in a lap joint, tee joint, or corner joint.
3.3.3.1.7 Full-fillet weld: A fillet weld whose size is equal to the thickness of the thinner
joined member.
3.3.3.1.8 Tack weld: A weld made to hold the parts of a element in proper alignment until
the final welds are made.

3.3.3.2 Weld Size:

The size of a groove weld shall be based on the joint penetration (that is, the depth of
chamfering plus the root penetration when specified).

3.3.3.3 Restrictions on Joints:

There are also some restrictions in welded joints mentioned in standards according to the
thicknesses and position of sheets/plates.

30


3.3.3.4 Typical Joints

3.3.3.4.1 Vertical Shell Joints:

Vertical shell joints shall be butt joints with complete penetration and complete fusion
attained by double welding or other means that will obtain the same quality of deposited weld
metal on the inside and outside weld surfaces. Vertical joints in adjacent shell courses shall
not be aligned but shall be offset from each other a minimum distance of 5t. Where, t is the
plate thickness of the thicker course at the point of offset.
3.3.3.4.2 Horizontal Shell Joints:
Horizontal shell joints shall have complete penetration and complete fusion; however, as an
alternative, top angles may be attached to the shell by a double-welded lap joint. Unless
otherwise specified, abutting shell plates at horizontal joints shall have a common vertical
centerline.
3.3.3.4.3 Lap-Welded Bottom Joints:
Lap-welded bottom plates shall be reasonably rectangular. Additionally, plate may be either
square cut or may have mill edges. Mill edges to be welded shall be relatively smooth and
uniform, free of deleterious deposits, and have a shape such that a full fillet weld can be
achieved. Lapping of two bottom plates on the butt-welded annular plates does not constitute
a three-plate lap weld.
3.3.3.4.4 Butt-Welded Bottom Joints:
Butt-welded bottom plates shall have their parallel edges prepared for butt welding with
either square or V grooves. Butt-welds shall be made using an appropriate weld joint
configuration that yields a complete penetration weld.
3.3.3.4.5 Bottom Annular-Plate Joints:
Bottom annular-plate radial joints shall be butt-welded in accordance with 3.1.5.5 and shall
have complete penetration and complete fusion. The backing strip, if used, shall be
compatible for welding the annular plates together.
3.3.3.4.6 Shell-to-Bottom Fillet Welds:
For bottom and annular plates with a nominal thickness 12.5 mm (1/2in.), and less, the
attachment between the bottom edge of the lowest course shell plate and the bottom plate
shall be a continuous fillet weld laid on each side of the shell plate.
3.3.3.4.7 Wind Girder Joints:
Full-penetration butt-welds shall be used for joining ring sections. Horizontal bottom-side
joints shall be seal-welded if specified by the purchaser. Seal-welding should be considered
to minimize the potential for entrapped moisture, which may cause corrosion.

31


3.3.3.4.8 Roof and Top-Angle Joints:
Roof plates shall, as a minimum, be welded on the top side with a continuous full-fillet weld
on all seams. Butt-welds are also permitted. Roof plates shall be attached to the top angle of a
tank with a continuous fillet weld on the top side only.

3.3.3.5 Loads

Loads are defined as follows:
3.3.3.5.1 Dead load (D
L
): The weight of the tank or tank component, including any
corrosion allowance.
3.3.3.5.2 Stored liquid (F): The load due to filling the tank to the design liquid level with
liquid with the design specific gravity.
3.3.3.5.3 Hydrostatic test (H
t
): The load due to filling the tank with water to the design
liquid level.
3.3.3.5.4 Minimum roof live load (L
r
): 1kPa (20 lbf/ft) on the horizontal projected area of
the roof.
3.3.3.5.5 Snow (S): The design snow load shall be 0.84 times the ground snow load.
Alternately, the design snow load shall be determined from the ground snow load in
accordance with ASCE 7.
3.3.3.5.6 Wind (W): The design wind speed (V) shall be 190 km/hr (120 mph), the 3 second
gust design wind speed determined from ASCE 7.
3.3.3.5.7 Design internal pressure (P
i
): Shall not exceed 18 kPa (2.5lbf/in2).
3.3.3.5.8 Design external pressure (P
e
): Shall not be less than 0.25kPa (1 in. of water) and
shall not exceed 6.9 kPa(1.01 lbf/in
2
).
3.3.3.5.9 External Pressure: Tanks that meet the requirements of this standard may be
subjected to a partial vacuum of 0.25 kPa (1 in. of water), without the need to provide any
additional supporting calculations.











32


3.3.4 Marking

3.3.4.1 Nameplates
A tank made in accordance with this standard shall be identified by a nameplate.
The nameplate shall be attached to the tank shell adjacent to a manhole or to a
manhole reinforcing plate immediately above a manhole.
A nameplate that is placed directly on the shell plate or reinforcing plate shall be
attached by continuous welding or brazing all around the nameplate.
When a tank is fabricated and erected by a single organization, that
organizations name shall appear on the nameplate as both fabricator and erector.
When a tank is fabricated by one organization and erected by another, the names
of both organizations shall appear on the nameplate, or separate nameplates shall
be applied by each.




Figure 24 Name plate for a tank
33

CHAPTER 4: TANK DESIGN

4.1 Introduction

Storage tank design consists of 2 main sections Shell Design and Roof Design. The shell
design include the shell stress design which is to size up the shell wall thickness, top and
intermediate stiffener ring, stability check against the wind and seismic load and sizing up the
anchor bolt. The roof design will consist of roof stress design, and the roof accessories and
fitting design.

4.2 Shell Design

For practical reasons, it is necessary to build up the shell from a number of fairly small
rectangular pieces of plate, butt welded together. Each piece will be cylindrically curved and
it is convenient to build up the shell in a number of rings, or courses, one on top of the other.
This technique provides, at least for deeper tanks, a convenient opportunity to use thicker
plates in the lower rings and thinner plates in the upper rings.

The lowest course of plates is fully welded to the bottom plate of the tank providing radial
restraint to the bottom edge of the plate. Similarly, the bottom edge of any course which sits
on top of a thicker course is somewhat restrained because the thicker plate is stiffer.


Figure 25Diagrammatic variation of stress in a shell







34

4.3Calculating Shell Thickness

API 650 gives two methods for calculating the required plate thickness for each shell course
:the one-foot method and the variable design point method.

4.3.1 One-Foot Method

The one-foot method is based on limiting the approximate membrane stress to the
allowable stress at a location that is 1 ft. above the bottom of the course being
considered. The required shell thickness is then determined based on that stress. A
distance of 1 ft. above the bottom of the course is assumed to be the location of
maximum membrane stress.
Thismethodshallnotbeusedfortankslargerthan200ft.indiameter.Anassumptionismadetha
teachshellcourseisstiffenedeitherbythetankbottomorthethicker
shellcourseimmediatelybelow.Therefore,ineffect,eachshellcourseisreinforcedatitslower
circumferentialseam,andthemaximumstressthatoccursinashell
courseisshiftedabovethecircumferentialseam.Thedistancethatthemaximum
stressisshiftedisconservativelysetatonefoot,whichgivesthedesignmethodits name.

4.3.2 Variable Design Point Method

Design by the variable design point method gives shell thicknesses at design points that
result in the calculated stresses being relatively closed to the actual circumferential shell
stresses this method may only be used when the purchaser has not specified that the one-
foot method be used and when the following is true.


Whereas per API 650 sec 5.6.4
L = (500Dt)
0.5
, in mm
D = tank diameter, in m
t = bottom course shell thickness excluding any corrosion allowance, in mm
H = design liquid level ,in m

Figure 26 Tank Shell Courses thicknesses
35


4.4 Shell Design by One foot method
The required minimum thickness of shell plates shall be the greater of the value computed as
followed [API 650, 2007 sec 5.6.3]:
Design shell thickness


Hydrostatic test shell thickness


Where

t
d
= design shell thickness, mm
t
t
= hydrostatic test shell thickness, mm
D = nominal tank diameter, m
H = design liquid level, m
G = design specific gravity of the liquid stored
C.A = corrosion allowance, mm
Sd = allowable stress for the design condition, MPa
St =
allowable stress for the hydrostatic test condition, MPa


The equation in the API 650 (2007) 1-Foot Method can be derived from the basic membrane
theory, the two main stresses exerting on the cylindrical shell due to the internal pressure are
longitudinal stress and circumferential stress. Lets look into each stress individually by
analyzing the stresses in the thin-walled cylindrical shell which an internal pressure exerted
on it.










CA
S
G H D
t
d
L
d
+

=
) 3 . 0 ( 9 . 4
1
t
L
t
S
H D
t
) 3 . 0 ( 9 . 4
1

=
36

4.4.1 Longitudinal Stress

Figure shows a thin walled cylindrical in which the longitudinal force FL resulted from
the internal pressure, Pi, acting on the thin cylinder of thickness t, length L, and diameter
D.



Figure 27 Longitudinal forces acting on thin cylinder under internal pressure


Longitudinal force =



Area resisting Fl , A = as shaded in above diagram

Longitudinal stresses =




Sl =



=














37

4.4.2Circumferential Stress

Similarly Figure 2.2 considers the circumferential stresses caused by internal pressure, Pi,
acting on the thin cylinder of thickness t, length L, and diameter D.




Figure 28 Circumferential forces acting on thin cylinder under internal pressure


Circumferential force =


Area resisting Fc , A = as shaded in above diagram


circumferential stress Sc =




Sc=



=




4.4.3Longitudinal Stress versus Circumferential Stress

Comparing the both thickness equations due to the longitudinal stress and circumferential
stress, with a specific allowable stress, pressure and fixed diameter, the required wall
thickness to withstand the internal pressure, Pi, for circumferential stress will twice that
required for the longitudinal stress. Circumferential stress in the thin wall will be the
governing stress and hence the Circumferential Stress Thickness Equation (tc) is used.


38

4.4.4 Circumferential Stress Thickness Equation and 1-Foot Method

From the Circumferential Stress Thickness Equation, replace the internal pressure, pi to
the hydrostatic pressure due to product liquid head , consider the effective head at
0.3 m height (H 0.3), and consider the corrosion allowance (C.A) by adding in to the
equation of circumferential stress. The minimum required thickness from the 1-Foot
method can be now be derived.




Circumferential Stress Thickness equation to 1-Foot method equation

4.5Top Stiffener and Intermediate Wind Girder Design

4.5.1 Top Stiffener/ Top Wind Girder

Stiffener rings of top wind girder are to be provided in an open-top tank to maintain the
roundness when the tank is subjected to wind load. The stiffener rings shall be located at
or near the top course and outside of the tank shell. The girder can also be used as an
access and maintenance platform. There are five numbers of typical stiffener rings
sections for the tank shell given in API 650 (2007) and they are shown in Figure 30 [API
650, 2007].


Figure 29 Stiffener ring
39

The requirement in API 650 (2007) stated that when the stiffener rings or top wind girder
are located more than 0.6 m below the top of the shell, the tank shall be provided with a
minimum size of 64 x 64 x 4.8 mm top curb angle for shells thickness 5 mm, and with a
76 x 76 x 6.4 mm angle for shell more than 5 mm thick. . The top wind girder is designed
based on the equation for the minimum required section modules of the stiffener ring
[API 650, 2007, sec 5.9.6].


Where

Z = Minimum required section modulus, cm

D = Nominal tank diameter, m

H2= Height of the tank shell, in m, including any freeboard provided above themaximum
filling height

V = design wind speed (3-sec gust), km/h

4.5.2 Intermediate Wind Girder

The shell of the storage tank is susceptible to buckling under influence of wind and
internal vacuum, especially when in a near empty or empty condition. It is essential to
analysis the shell to ensure that it is stable under these conditions. Intermediate stiffener
or wind girder will be provided if necessary.

To determine whether the intermediate wind girder is required, the maximum height of
the un-stiffened shell shall be determined. The maximum height of the un-stiffener shell
will be calculated as follows [API 650, 2007,sec 5.9.7.1]:

Where

H1 = Vertical distance, in m, between the intermediate wind girder and top wind girder

t = Thickness of the top shell course, mm

D = Nominal tank diameter, m

V = design wind speed (3-sec gust), km/h

As stated in earlier section, the shell is made of up diminishing thickness and it makes
the analysis difficult. The equivalent shell method is employed to convert themulti-
40

thickness shell into an equivalent shell having the equal thickness as to the top shell
course.

The actual width of each shell course in changed into a transposed width of each shell
course having the top shell course thickness by the following formula [API 650,
2007,sec 5.9.7.2]:


Where

W tr= Transposed width of each shell course, mm

Wt = Actual width of each shell course, mm

tuniform= Thickness of the top shell course, mm

tactual= Thickness of the shell course for which the transpose width is being calculated, mm




Figure 30 Wind Girders

Situations exist where just a top wind girder alone will not provide enough shell stiffness for
a given combination of tank height, tank diameter, and tank shell course thicknesses. Put in
simple terms, the distance between the top wind girder and the tank bottom is too large, in
41

these situations, to resist wind-induced shell deformation. Installation of an intermediate wind
girder at a location between the top wind girder and the tank bottom reduces the un stiffened
length of the shell, and is required in order to prevent shell deformation in these cases.

Intermediate wind girder design calculations in accordance with API-650 requirements
consist of the following general steps:

Determine if an intermediate wind girder is needed, based on design wind
velocity, tank diameter, and shell course thicknesses.
Locate the intermediate wind girder.
Calculate the minimum required section modulus of the intermediate wind
girder and select a standard structural shape that provides this section
modulus.

The API-650 procedure for locating the intermediate wind girder considers the variation in
shell course thickness. As illustrated in Figure 32, the API-650 procedure mathematically
converts the actual tank shell height to a "transformed shell" height. As detail in design
calculation chapter the shell transformation is done by accounting for the actual individual
course thicknesses. The transformed shell then has the same stiffness throughout its height
Locating the intermediate wind girder at the mid-height of the transformed shell results in
equal shell stiffness both above and below the intermediate wind girder. The intermediate
wind girder is then located on the actual tank shell in the same course and in the same relative
position within that course as it is on the transformed shell. Using this approach, the
intermediate wind girder is located much higher than the mid-height on the actual tank shell.





Figure31 Transformed shell and intermediate wind girder


42

4.6 Bottom Plate Designing
For oil storage tanks, steel bottom plates are specified, laid and fully supported on a prepared
foundation.
Since it is in common practice if the diameter of tank is greater is than 12m than we have to
incorporate annular plate in bottom plate to make it more strengthen. According to API 650
5.4 all bottom plates shall have a minimum nominal thickness of 6mm exclusive of any
corrosion allowance specified by the purchaser for the bottom plates.
The bottom is made up of a number of rectangular plates, surrounded by a set of shaped
plates, called sketch plates, to give a circular shape, as shown in Figure 33. The plates slightly
overlap each other and are pressed locally at the corners where three plates meet (see Figure
34). Lapped and fillet welded joints are preferred to butt welded joints (which must be
welded onto a backing strip below the joint) because they are easier and cheaper to make.




Figure 32Bottom layout for tank
See figure 34
details A and B
43



Figure 33 Cross joints in bottom plates

4.7 Roof Design

We have selected conical roof with self-supported at its periphery since it is easy to construct
and design comparing with other types of roof. But it is strongly dependent to customer that
what type of roof selected for storage tank.
Fixed roofs of cylindrical tanks are formed of steel plate and are of either conical or domed
(spherically curved) configuration. The steel plates can be entirely self-supporting (by
'membrane' action), or they may rest on top of some form of support structure.
Membrane roofs are more difficult to erect - they require some temporary support during
placing and welding and are usually found only on smaller tanks.
Permanent support steelwork for the roof plate may either span the complete diameter of the
tank or may in turn be supported on columns inside the tank. The use of a single central
column is particularly effective in relatively small tanks (15-20 m diameter), for example.
The main members of the support steelwork are, naturally, radial to the tank. They can be
simple rolled beam sections or, for larger tanks, they can be fabricated trusses.
Roof plates are usually lapped and fillet welded to one another. For low pressure tanks, they
do not need to be welded to any structure which supports them, but they must normally be
welded to the top of the shell.







44


4.8 Overturning Stability against Wind Load

The overturning stability of the tank shall be analyzed against the wind pressure, and to
determine the stability of the tank with and without anchorage. The wind pressure used in the
analysis is given as per API 650 (2007, sec 5.11). The design wind pressure on the vertical
projected areas of cylindrical surface area shall be 0.86 kPa (V/190) and 1.44 kPa (V/190)
uplift on horizontal projected area of conical surface. These design wind pressure are in
accordance with American Society of Civil Engineer - ASCE 7 for wind exposure Category
C [ASCE 7, 2005]. The loading diagram due to the wind pressure on the roof tank is shown
in following Figures.





Figure 34 Overturning moment against wind load




Figure 35 Shell Out of Roundness Caused By Wind
45

The wind load (Fs) on the shell is calculated by multiplying the wind pressure (ws) to the
projected area of the shell.
As per API 650 (2007), the tank will be structurally stable without anchorage when the below
uplift criteria are meet [API 650, 2007, sec 5.11.2].




Where
Mpi= moment about the shell-to-bottom from design internal pressure (Pi) and it can be
calculated by the formula



Mw= Overturning moment about the shell-to-bottom joint from horizontal plus vertical wind
pressure and is equal to Fr. Lr + Fs. Ls. Fr and Fs is the wind load acting on the roof and shell
respectively and Lr and Ls is the height from tank bottom to the roof center and shell center
respectively.

MDL= Moment about the shell-to-bottom joint from the weight of the shell and roof supported
by the shell and is calculated as 0.5 D.WDL.


MF= Moment about the shell-to-bottom joint from liquid weight and is equal to















46

4.9 Seismic Design

The seismic design of the storage tank is accordance to API 650 (2007) Appendix E. There
are two major analyses to be performed in the seismic design, and they are:

i)Overturning Stability check - The overturning moment will be calculated and check for the
anchorage requirement. The number of anchor bolt required and the anchor bolt size will also
be determined based on the overturning moment.

ii)Maximum base shear



4.9.1Overturning Stability against seismic load

The seismic overturning moment at the base of the tank shall be the square root of sum of
squares (SRSS) summation of the impulsive and convective components multiply by the
respective moment arms to the center of action of the forces.

For tanks supported by the concrete ring wall, the equation for calculating the ring wall
moment, Mrw is as follow [API 650, 2007, sec E.6.1.5]:

Where

Ai = Impulsive design response spectrum acceleration coefficient, %g

Ac = Convective design response spectrum acceleration coefficient, %g

Wi = Effective impulsive portion of liquid weight, N

Ws = Total weight of the tank shell and appurtenances, N

Wr = Total weight of fixed tank roof including framing, knuckles, any permanent attachments
and 10% of the roof design snow load, N

Wc = Effective convective (sloshing) portion of liquid weight, N

Xi = Height from the bottom of the tank shell to the center of action of the lateral seismic
force related to the impulsive liquid force for ring wall moment, m

Xs = Height from the bottom of the tank shell to the shells center of gravity, m

Xr = Height from the bottom of the tank shell to the roof and roof appurtenances center of
gravity, m

Xc = Height from the bottom of the tank shell to the center of action of the lateral seismic
force related to the convective liquid force for ring wall moment, m

47

This overturning moment is important for the mechanical to design the anchorage
requirement and determine the minimum the number and size of the anchor bolt for the
storage tank. It is also important to the civil engineer to design the tank foundation in which
the tank is being supported.


4.10 Anchorage requirement

The resistance to the design ring wall overturning moment at the base of the shell will be
provided by the weight of the tank shell, weight of the roof reaction, Wrs, by the weight of a
portion of the tank contents adjacent to the shell for unanchored tanks or provided by the
mechanical anchorage devices.

The anchorage requirement is checked by the Anchorage Ratio, J, and the anchorage ratio
criteria in Table will determine whether the tank can be self-anchored or mechanically
anchored.






Table 2Anchorage Ratio Criteria [API650, 2007, table E-6]












48

The anchorage ratio, J is determined as follow [API650, 2007, sec E.6.2.1.1.1]:



Where

wt = Weight of tank shell & portion of roof supported by shell and is define as




wa = Resisting force of annulus which is defined as





Where

Fy= Min. specified yield strength of bottom annulus

H = Maximum design product level

Ge = Effective specific gravity including vertical seismic effect

= G(1 - 0.4 Av) ; G = 1, Specific gravity

Av = Vertical earthquake acceleration coefficient

Wint= Uplift due to product pressure

wrs= Roof load acting on shell, including 10% of specified snow load










49


CHAPTER:05 DESIGN CALCULATIONS

5.1 Material selection
The first step is to select material for shell, bottom plate, annular plate, roof plate etc.
The factors that govern that material selection are as follows:
Cost
Availability
Strength
Inertness


ASTM 283 Grade C is selected as shell, bottom, annular and roof plate material. The yield
strength of the material is given as 205 MPa. it belongs to group 1 material as listed in table
4-3a of API 650.
Material used in the construction of tanks shall conform to the specification listed in the API
sec 4, subject to the modification and limitation indicated in this standard material produced
to specification other than those listed in this section may be employed, provided that the
material is certified to meet all of the requirements listed in this standard and the material is
approved by the purchaser the manufacturer proposal shall identify the material specification
to be used.









50


5.2 Design specifications
Design Code API 650, 11
th
Edition
Fluid Sulphuric acid
Material SA 283 Gr. C(
m =
7850 kg/m
3
)
Specific Tank Diameter 5.6 meters
Tank Height 11.0 meters
Geometrical Capacity 270 m3
Design Liquid Level 10.49 m
gravity of contents G = 1.94
Materials yield strength d
y
= 205 MPa
Design Pressure (+ve) 3.0 IN WC (0.1083 psig
Design Pressure (-ve) 1.0 IN WC (0.036 psig)
Design Temperature (max) 50oC
Design Temperature (min) 5 oC
Roof Type Structurally Supported Fixed Cone Roof
Roof Slope 1:16
Bottom Type Flat non-annular with center sump
Bottom Slope 1:48
Allowable Product Design stress Sd = 137.0 Mpa
Allowable Hydrostatic test stress St = 154 MPa
Corrosion allowance
Bottom = 1.5mm
Shell = 1.5 mm
Roof = 1.5mm
Joint Efficiency 0.85
Wind Speed 120 mph
Seismic Zone 2B
Plate Size 1500 mm x 6000 mm
Modulus of Elasticity E = 199000 MPa
Yield strength of steel structure (Stiffeners) Fy = 250 MPa

51

Material
Shell Material HR-235
Roof Material HR-235
Bottom Material HR-235
Structure Material ASTM A-36
Pipe Material A-106 Gr. B
Flange Material A-105, 150#, Welding Neck
Gasket Material Spiral Wound
Anchor Bolt Material ASTM A-36
Venting Type Vent to closed loop/ vapor return
Painting Yes (Only External)
Internal Lining Yes (Rubber lining 3mm thick compatible
with H2SO4)
Insulation Yes
Insulation Thickness 2 Inch
Insulation Density 50 kg/m3
Tank Foundation Ring Wall










52

5.3 Basic Calculations
Height = H= 11.0 m (Given)
Diameter =D = 5.6 m (Given)
Aspect Ratio =


= 1.96
Total working capacity =


= 270


= 9567.84



5.4 Shell Design
As per API 650 5.6.3
Calculations of Shell Thicknesses
The required shell plates thickness shall be greater of the values computed by following
formulas.
Design Shell Thickness (As per API 5.6.3)

Hydrostatic Test Thickness (As p (as per API 5.6.3)

Height for each shell course H
Li
= H
L(i-1)
- (i-1)W
G = Specific Gravity of fluid to be stored
D = Nominal dia. of tank (m)
H
L1
= Design liquid level (m) for course under consideration.
CA = Corrosion allowance. = 1.50 mm
t
d
= Design shell thickness (mm)
CA
S
G H D
t
d
L
d
+

=
) 3 . 0 ( 9 . 4
1
t
L
t
S
H D
t
) 3 . 0 ( 9 . 4
1

=
53

t
t
= Hydrostatic test shell thickness (mm)
H
Lo
= Total Height of the Tank Shell = 11.00 m
W = Width of the Plate (Course) = 2.45 m
i = Shell Course Number = 1 to 7
1st Shell Course
Width of 1st. Course W
1
=1.5 m
Design height for 1st shell Course H
L1
= 11.0 m
Required Shell Thickness t
t =
2.15mm
Required Shell Thickness t
d
= 3.92mm

Shell thickness selected t
1
= 6.00 mm



2
nd
Shell Course
Width of 2
nd
Course W
2
=1.50 m
Design height for 2
nd
shell Course H
L2
=9.5 m
Required Shell Thickness t
t
=1.84mm
Required Shell Thickness t
d
= 3.57mm

Shell thickness selected t
2
= 6.00 mm

3
rd
Shell Course
Width of 3
rd
Course W
3
=1.50 m
Design height for 3
rd
shell Course H
L3
=8.0 m
Required Shell Thickness t
t
=1.52 mm
Required Shell Thickness t
d
= 3.21mm

Shell thickness selected t
3
= 6.00 mm


54

4th Shell Course
Width of 4th Course W
4
=1.50 m
Design height for 4th shell Course H
L4
=6.5 m
Required Shell Thickness t
t
=1.21 mm
Required Shell Thickness t
d
= 2.86 mm

Shell thickness selected t
4
= 6.00 mm
5th Shell Course
Width of 5th Course W
5
=1.50 m
Design height for 5th shell Course H
L5
=5.0 m
Required Shell Thickness t
t
=0.89 mm
Required Shell Thickness t
d
= 2.50 mm

Shell thickness selected t
5
= 6.00 mm
6th Shell Course
Width of 6th Course W
6
=1.50 m
Design height for 6
th
shell Course H
L6
=3.5 m
Required Shell Thickness t
t
=0.58 mm
Required Shell Thickness t
d
= 2.15 mm

Shell thickness selected t
6
= 6.00 mm



7th Shell Course
Width of 7th Course W
7
=1.50 m
Design height for 7th shell Course H
L7
=2.0 m
Required Shell Thickness t
t
=0.26mm
Required Shell Thickness t
d
= 1.79 mm

Shell thickness selected t
7
= 6.00 mm
55



8th Shell Course
Width of 8th Course W
8
=0.50 m
Design height for 8th shell Course H
L8
=0.5 m
Required Shell Thickness t
t
= 0 mm
Required Shell Thickness t
d
= 1.49mm

Shell thickness selected t
8
= 6.00 mm



Shell Thickness & Weight Summary
Shell Course #
1 2 3 4 5 6 7
8
Shell width (m) 1.5 1.5 1.5 1.5 1.5 1.5 1.5
0.5
Shell Thick, corroded (mm) 6.0 6.00 6.00 6.00 6.00 6.00 6.00
6.00
Shell Weight (KN) 12.17 12.17 12.17 12.17 12.17 12.17 12.17
4.05
Shell Weight(corroded) (KN) 9.13 9.13 9.13 9.13 9.13 9.13 9.13
3.04

Total Shell Weight = 12.17(7)+4.05=89.24KN
Total Shell Weight (corroded) = 9.13(7)+ 3.04=66.95KN








56

5.5 Bottom Plate Design
As per API 650 5.4.1
All bottom plates shall have minimum nominal thickness of 6mm, exclusive of any corrosion
allowance as per API 650 5.4.1
Required Bottom Plate Thickness t
r
= 6 + CA mm
= 6+1.5 = 7.5 mm
Selected bottom plate thickness t
b
= 8.0 mm

Weight of Btm. Plate +Annular plate
For corroded weight
Weight of Btm. Plate +Annular plate

Weight of Btm. Plate +Annular plate = 7907.57 kg =>15.72 KN
Weight of Btm. Plate +Annular plate = 64.24.90 kg =>12.78KN (Corroded)

5.6 Annular Plate Design
(As per API 650 Sec. 5.5)
Product stress 137.00Mpa
Hydrostatic test stress 154.00 MPa
Annular bottom plate thickness t = 6 mm (As per API 650 Table 5-1 a)
Including corrosion allowance 7.50 mm
Used annular plate thickness t
b
= 8.00 mm
Max. design liquid level H
L1
= 10.5 m






( )
( ) ( ) { }
(

+ +
H
+
(

+ H
=
2 2
2
1 . 0 1 . 0
4 4
1 . 0
act
m b m b act
W D D
t t W D


( )
( ) ( ) { }
(

+ +
H
+
(

+ H
=
2 2
2
1 . 0 1 . 0
4
) (
4
) ( 1 . 0
act
m b m b act
W D D
CA t CA t W D


57

5.7 Intermediate Wind Girder Design
(As per API 650 Sec. 5.9.7)
The maximum height of the Un-stiffened shell shall be calculated as follows:
H
1
= 9.47 t(

(As per API 650 Sec. 5.9.7)


Where
H
1
= Vertical distance, in m, between the intermediate wind girder and the top angle of the
shall or the top wind girder of an open top tank.
t = Thickness of the top shell course = 6 mm
D = Nominal tank diameter (m) = 5.76 m
H
1
=30.68 m
Modification as per API 650 (5.9.7.1 Note 2, a)
H
1
= (

)xH
1

= 17.64 m

Transformed Shell thicknesses
W
tr(i) =
W
i
x (

(As per API 650 Sec. 5.9.7)


Where,
W
tr(i) =
Transformed Shell Thickness
W
i
=Width of Courses
(W
1 to 7
= 1.50 m ; W
8 =
0.50 m)
t
top
= Shell Thickness of 8
th
Course
t
i
= Thickness Of the Course that is consider
i = Shell Course Number = 1 to 8


58


1st Course
Thickness of first course t
1
= 6.00 mm
W
tr1
= W
1
x(



= 1499.61 mm
2nd Course
Thickness of 2nd course t
2
= 6.00 mm
W
tr2
= W
2
x (


= 1499.61mm
3rd Course
Thickness of 3rd course t
3
= 6.00 mm
W
tr3
= W
3
x (


= 1499.61 mm

4th Course
Thickness of 4th course t
4
= 6.00 mm
W
tr4
= W
4
x (


= 1499.61 mm
5th Course
Thickness of 5th course t
5
= 6.00 mm
W
tr5
= W
5
x (


= 1499.61 mm
59


6th Course
Thickness of 6th course t
6
= 6.00 mm
W
tr6
= W
6
x (


= 1499.61mm
7th Course
Thickness of 7th course t
7
= 6.00 mm
W
tr7
= W
7
x (


= 1499.61mm
8th Course
Thickness of 7th course t
7
= 6.00 mm
W
tr7
= W
7
x (


= 489.87mm


Height of transformed shell, H
tr
= W
tr1
+W
tr2
+W
tr3
+W
tr4
+W
tr5
+W
tr6
+W
tr7+
W
tr8

Height of transformed shell, H
tr
=10987.14 mm or 10.98 m
As
H
tr
< H
1

10.98 < 17.64
Intermediate Wind Girder is Not Required.



60

5.8 Roof Design (Supported Conical Roof) As per API 650(5.10.5)
Minimum roof thickness is 5mm (As per API 650(5.10.5)
Roof plate thickness = 6.5 mm (with corrosion allowance)
Selected Roof Plate thickness= t
h
= 7 mm
= slope of roof = 3.57
D
o
= Outer Diameter= 5.6 m
= 850 kg/m
3

Vertical Projected Area of Roof =


pt = 0.75 in/ft (Cone Roof Pitch)
Horizontal Projected Area of Roof (Per API-650 5.2.1.f):
Xw = Moment Arm of UPLIFT wind force on roof
=

=
Ap = Projected Area of roof for wind moment
=


R = 9.184 ft
Dead Load = Insulation + Plate Weight + Added Dead Load


Roof Loads (per API-650 Appendix R)


61


e.1b = DL + MAX(Sb,Lr) + 0.4Pe


e.2b = DL + Pe + 0.4MAX(Sb,Lr)


T = Balanced Roof Design Load (per API-650 Appendix R)
= MAX(e.1b,e.2b)


e.1u = DL + MAX(Sb,Lr) + 0.4Pe

e.2u = DL + Pe + 0.4MAX(Su,Lr)


U = Unbalanced Roof Design Load (per API-650 Appendix R)
= MAX(e.1u,e.2u)
= 33.833



P = Max. Design Load = Lr1




l = Maximum Rafter Spacing (Per API-650 5.10.4.4)






62

MINIMUM # OF RAFTERS

FOR OUTER SHELL RING:

l = 84 in. since calculated l > 84 in. (7 ft)




Minimum roof thickness based on actual rafter spacing:






RLoad

= Maximum Roof Load based on actual rafter spacing




Let
Max

= RLoad

(Vacuum limited by actual rafter spacing)



= -0.3336 PSI or -9.25 IN. H2O

Pa

= P


= -0.3336 PSI or -9.25 IN H2O.

t

=0.2465 in.


63

5.9 RAFTER DESIGN
Maximum Rafter Span = 9.184 ft
Average Rafter Spacing on Shell = 6.282 ft
Average Plate Width=

=3.141 ft
M

= Maximum Bending Moment


M


where,


l = (9.184)(12)
= 110.21 in.
Mmax = (9.66)(110.21)


Z req'd = Mmax/23,200

(Max. stress allowed for each rafter in ring 1)





Max

(Max. Load allowed for each rafter in ring 1)




64

Let
Max

= Max

144

P

(Vacuum limited by Rafter Type)




= -1 PSI due to Rafter Type
Pa2

= P


(limited by Rafter Type)

5.10 COLUMN DESIGN :
CENTER COLUMN
l = Column Length



r = Radius of gyration
if l/r must be less than 180, then



Actual r = 2.93 in. using Pipe 8 Inch Sch. 40




65






Fa = Allowable Compressive Stress (Per API-650 5.10.3.4)
R = L/r = 150.2 (actual) Per API-650 5.10.3.3,
Cc = Column Slenderness Ratio



FS = Factor of Safety
= 5/3 + 3(150.2)/(8(125.7)) - (150.2)

/(8(125.7)3)
= 1.9015
Since R <= 120,
Using AISC Specification Formulas Section E2,
(let K = 1)



Fa is not modified Since Design Temp. <= 200 F.
(API-650 M.3.5 N.A.)

= 6574 PSI


66


A

= P/Fa
= [4,791 + (440/12)(28.55)]/6,574
= 0.89 in



F = actual induced stress for the column
= P/A

[ (

)]

(Max. weight allowed for each column in ring 1)




Max

(Max. Load allowed for each column in ring 1)


Let

(Vacuum limited by Column Type)




= -1 PSI due to Column Type

Pa

= P


(limited by Column Type)

67



ROOF WEIGHT
Weight of Roof Plates





Weight of Roof Plates supported by shell















68

5.11 Tank Overturning Stability

WIND MOMENT (Per API-650 SECTION 5.11)
vs = Wind Velocity = 120 mph
vf = Velocity Factor = (vs/120)


= (120/120)


= 1


API-650 5.2.1.k Uplift Check


69


Ap

= Vertical Projected Area of Roof




Horizontal Projected Area of Roof (Per API-650 5.2.1.f)
Xw = Moment Arm of UPLIFT wind force on roof



Ap = Projected Area of roof for wind moment

(Moment Due to Wind Force on Roof)





Xs (Moment Arm of Wind Force on Shell)



As (Projected Area of Shell)
70

(Moment Due to Wind Force on Shell)





Mw (Wind moment)





W = Net weight (PER API-650 5.11.3)
(Force due to corroded weight of shell and
shell-supported roof plates less
40% of F.1.2 Uplift force.)








71

5.12.1 RESISTANCE TO OVERTURNING (per API-650 5.11.2)

An unanchored Tank must meet these two criteria:
1) 0.6Mw + MPi < MDL/1.5
2) Mw + 0.4MPi < (MDL + MF)/2

Mw = Destabilizing Wind Moment = 365,138 ft-lbf

Mpi = Destabilizing Moment about the Shell-to-Bottom Joint from Design Pressure.




MDL = Stabilizing Moment about the Shell-to-Bottom Joint from the Shell and
Roof weight supported by the Shell.





tb = Bottom Plate thickness less C.A. = 0.2559 in.
wl = Circumferential loading of contents along Shell-To-Bottom Joint.





wl = 0.9 H

D
o
(lesser value than above)
72




MF = Stabilizing Moment due to Bottom Plate and Liquid Weight.
= (D
o
/2)wlPI D
o



Criteria 1

Since 257,035 >= 106,528, Tank must be anchored.


Criteria 2

Since 380319 >= 230758 Tank must be anchored.

RESISTANCE TO SLIDING (per API-650 5.11.4)

F

= vF 18 As



F

= Maximum of 40% of Weight of Tank











73



Bolt Shear Area Req'd = 0.055 in



Anchorage Requirement
Anchorage required since Criteria 1, Criteria 2, or Sliding are NOT acceptable.
Bolt Spacing = 10 ft,
Min # Anchor Bolts = 6
5.12 .2Stability of Tank Against Seismic Load
Seismic design provide minimum requirements for the design of welded steel tanks that may
be subjected to seismic ground motion, since seismic loads are strongly dependent on
geography condition of site therefore we assumed a lot of factors that are related to the site of
the storage tank for detail of coefficient used under this section see API 650 E.2.2
Check against Seismic Failure as stated by UBC 97 & appendix E of API 650
D = 5.6 m
H =11 m
D/H = 0.50
H/D = 1.96
WEIGHTS
Ws = Weight of Shell (Incl. Shell Stiffeners & Insul.)

Wf = Weight of Floor (Incl. Annular Ring)

Wr = Weight Fixed Roof, framing and 10% of Design Live Load & Insul.



74

5.12.3 SEISMIC VARIABLES
SUG = Seismic Use Group (Importance factor depends on SUG)
= I
Site Class = E
Sp = Design level peak ground acceleration parameter for sites not addressed by
ASCE methods

Ss = Design Spectral Response Param. (5% damped) for Short Periods
(T=0.2 sec)(Ss = 2.5Sp per E.4.3 formula E.4.3-1)

S1 = Design Spectral Response Param. (5% damped) for 1-Second Periods
(T=1.0 sec)(S1 = 1.25Sp per E.4.3 formula E.4.3-2)


T

= Regional Dependent Transition Period for Long Period Ground Motion


(per API-650 E.4.6.1 for regions outside the USA)

Av = Vertical Earthquake Acceleration Coefficient

Q = Scaling factor from the MCE to design level spectral accelerations

Fa = Acceleration-based site coefficient (at .2 sec period)(Table E-1)

Fv = Velocity-based site coefficient (at 1 sec period)(Table E-2)

I = Importance factor defined by Seismic Use Group

75

Rwi = Force reduction factor for the impulsive mode using allowable
stress design methods.

Rwc = Force reduction factor for the convective mode using allowable
stress design methods.

Ci = Coefficient for impulsive period of tank system (Fig E-1)

tu = Equivalent uniform thickness of tank shell

Density = Density of tank product. SG62.4


E = Elastic modulus of tank material (bottom shell course)
Sds = The design spectral response acceleration param. (5% damped) at short periods
(T = 0.2 sec) based on ASCE7 methods.



Sd1 = The design spectral response acceleration param. (5% damped)
at 1 second based on ASCE7 methods.
= QFvS1






76

5.12.4 STRUCTURAL PERIOD OF VIBRATION
E.4.5.1 Impulsive Natural Period



E.4.5.2 Convective (Sloshing) Period
Ks = 0.578/SQRT(TANH(3.68H/D))


Tc = KsSQRT(D)



E.4.6.1 Spectral Acceleration Coefficients
Ai = Impulsive spectral acceleration parameter




K = Coefficient to adjust spectral acceleration from 5% - 0.5% dampin

Ac = Convective spectral acceleration parameter




77

Chp:06 RESISTANCE TO DESIGN LOADS

6.1 EFFECTIVE WEIGHT OF PRODUCT
D/H = Ratio of Tank Diameter to Design Liquid Level

Wp = Total Weight of Tank Contents based on S.G.

Wi = Effective Impulsive Portion of the Liquid Weight



Wc = Effective Convective (Sloshing) Portion of the Liquid Weight




Weff = Effective Weight Contributing to Seismic Response
= Wi + Wc

Wrs = Roof Load Acting on Shell, including 10% of Live Load

6.1.1 DESIGN LOADS
Vi = Design base shear due to impulsive component from effective weight of tank and
contents
= Ai(Ws + Wr + Wf + Wi)


78

Vc = Design base shear due to convective component of the effective sloshing weight
= AcWc


V = Total design base shear





6.2.1 CENTER OF ACTION FOR EFFECTIVE LATERAL FORCES

Xs = Height from Bottom to the Shell's Center of Gravity

RCG = Height from Top of Shell to Roof Center of Gravity

Xr = Height from Bottom of Shell to Roof Center of Gravity



6.2.2 CENTER OF ACTION for RINGWALL OVERTURNING MOMENT

Xi = Height to Center of Action of the Lateral Seismic force related to
the Impulsive Liquid Force for Ring wall Moment



Xc = Height to Center of Action of the Lateral Seismic force related to
79

the Convective Liquid Force for Ring wall Moment




6.2.3 CENTER OF ACTION for SLAB OVERTURNING MOMENT
Xis = Height to Center of Action of the Lateral Seismic force related to
the Impulsive Liquid Force for the Slab Moment
=

=

Xcs = Height to Center of Action of the Lateral Seismic force related to
the Convective Liquid Force for the Slab Moment
= (1-(cosH(3.67H/D)-1.937)/((3.67H/D)sinH(3.67H/D)))H
=
=
6.2.4 Dynamic Liquid Hoop Forces









80

SHELL SUMMARY
Shell

Width
Ft
Y
ft
Ni


Nc


Nh
lbf
Sig(+)


Sig(-)


1 4.92 33.44 3.28 0.003 1935 10951 10914
2 4.92 28.52 3.28 0.004 1659 9391 9354
3 4.92 23.6 3.28 0.011 1382 7826 7789
4 4.92 18.68 3.28 0.029 1106 6267 6230
5 4.92 13.76 3.27 0.078 829 4702 4665
6 4.92 8.84 2.85 0.208 553 3140 3108
7 4.92 3.92 1.6 0.558 276 1569 1550
8 1.64 -1 -0.49 1.495 0 9 -9


6.2.5 Overturning Moment
Mrw = Ring wall momentPortion of the total overturning moment that acts at the
base of the tank shell perimeter
Mrw = ((Ai(WiXi+WsXs+WrXr))

+ (AcWcXc)



Ms = Slab moment (used for slab and pile cap design)
Ms = ((Ai(WiXis+WsXs+WrXr))

+ (AcWcXcs)









81

6.2.6 RESISTANCE TO DESIGN LOADS

E.6.2.1.1 Self-Anchored
Fy = Minimum yield strength of bottom plate
= 29732 psi
Ge = Effective specific gravity including vertical seismic effects






wa = Force resisting uplift in annular region




wa = 810 lbf/ft (reduced to 1.28HDGe because
that is the max allowable per E.6.2.1.1)

wt = Shell and roof weight acting at base of shell




wint = Uplift Load due to design pressure acting at base of shell
82




E.6.2.1.1.1 Anchorage Ratio
J = Mrw/(D

[wt(1-0.4Av)+wa-0.4wint])
= 59,140/(18.368

[436.6302(1-0.40)+810-0.428.6453])
= 0.1419
The tank is self anchored.

E.6.2.2 Maximum Longitudinal Shell-Membrane Compressive Stress
E.6.2.2.1 Shell Compression in Self-Anchored Tanks
ts1 = Thickness of bottom shell course minus C.A.
= 0.177 in.
Sig C = Maximum longitudinal shell compression stress




E.6.2.2.3 Allowable Longitudinal Shell-Membrane Compression Stress
Fty = Minimum specified yield strength of shell course


Fc = Allowable longitudinal shell-membrane compressive stress


83

6.3 ANCHOR BOLT DESIGN

Bolt Material : A-36
Sy = 36000 PSI

Uplift Load Cases, per API-650 Table 5-21b

D (tank OD) = 18.368 ft
P (design pressure) = 3 INCHES H2O
Pt (test pressure per F.4.4) = P = 3 INCHES H2O
Pf (failure pressure per F.6) = N.A. (see Uplift Case 3 below)
t

(roof plate thickness) = 0.2755 in.


Mw (Wind Moment) = 365138 ft-lbf
Mrw (Seismic Ring wall Moment) = 59140 ft-lbf
W1 (Dead Load of Shell minus C.A. and Any Dead Load minus C.A. other than
Roof Plate Acting on Shell)
W2 (Dead Load of Shell minus C.A. and Any Dead Load minus C.A. including Roof
Plate minus C.A. Acting on Shell)

W3 (Dead Load of New Shell and Any Dead Load other than Roof Plate Acting on
Shell)

For Tank with Structural Supported Roof,
W1 = Corroded Shell + Shell Insulation



84

W2 = Corroded Shell + Shell Insulation + Corroded Roof Plates
Supported by Shell + Roof Dead Load Supported by Shell


W3 = New Shell + Shell Insulation



Uplift Case 1: Design Pressure Only






Uplift Case 2: Test Pressure Only





Uplift Case 3: Failure Prssure Only
Not applicable since if there is a knuckle on tank roof,
or tank roof is not frangible.



85

Uplift Case 4: Wind Load Only









86

Uplift Case 5: Seismic Load Only





Uplift Case 6: Design Pressure + Wind Load



Uplift Case 7: Design Pressure + Seismic Load


87




Uplift Case 8: Frangibility Pressure
Not applicable since if there is a knuckle on tank roof,
or tank roof is not frangible.

6.4 CAPACITIES and WEIGHTS

Maximum Capacity (to upper TL) : 71214 gal
Design Capacity (to Max Liquid Level) : 67975 gal
Minimum Capacity (to Min Liquid Level) : 0 gal
NetWorking Capacity (Design - Min.) : 67975 gal
Weight of Tank, Empty : 29644 lbf
Weight of Tank, Full of Product (SG=1): 623953 lbf
Weight of Tank, Full of Water : 623953 lbf
Net Working Weight, Full of Product : 596923 lbf
Net Working Weight, Full of Water : 596923 lbf
New condition Corroded
Shell 20064 lbf 15055 lbf
Roof plates 2983 lbf 2344 lbf
Rafters 793 lbf 793 lbf
Girders 0 lbf 0 lbf
Columns 1047 lbf 1047 lbf
Bottom 3536 lbf 2,874 lbf
Stiffeners 0 lbf 0
Nozzle Wgt 0 lbf 0
Misc Roof Wgt 0 lbf 0
Insulation 1221 lbf 1221 lbf
Total 29644 lbf 23334 lbf

88

START
SHELL DESIGN
Thickeness + weight
(corroded + uncorroded)
As per 5.6 of API 650
BOTTOM PLATE DESIGN
Thickeness + weight
(corroded + uncorroded)
As per 5.4 of API 650
A
A
1
ANNULAR PLATE DESIGN
Thickeness + weight
(corroded and uncorroded)
If D12
As per 5.5 of API 650
Annular Bottom
Plate is NOT
required
No
Annular Bottom
Plate is
Neccessary
Yes
WIND GIRDER DESIGN
If unstiffened shell height H1>transposed
height
i.e H1>Htrans
As per 5.9 of API 650
Intermediate wind
girder is required
No
Find Min. no of
Wind girder
Find Location of
wind girder
Intermediate wind
girder is NOT
required
Yes
ROOF DESIGN
Plate thickeness+weight,radius,
(corroded+uncorroded)
As per 5.10 of API 650
RAFTER DESIGN
Quantity+spacing
STIFFENER DESIGN
Length+quatity+spacing
+weight
As per IPE 200
COMPRESSION RING DESIGN
At shell to roof junction
As per appendix F of API 650
CHECK FRANGIBILITY
CONDITION
If max area reqd for frangibility
condition> Areqd
Find FAILURE pressure Pf + Max
DESIGN pressure Pmax
As per appendix F of API 650
No
Improve Roof
Design
Yes
If Pmax Pf No
Recheck shell
Thickeness against Pf
If tprov > treqd
Yes
NO
Yes

STORAGE TANK DESIGN FLOW CHART
89



STORAGE TANK DESIGN FLOW CHART
Check against WIND load
As per 5.11.2 of API 650
Anchorage
Against wind
pressure is NOT
required
satisfactory
Anchorage against
wind pressure is
Required
Unsatisfactory
Check for SLIDING
FAILURE
as per 5.11.4 of API 650
Anchorage against
sliding is NOT
required
Satisfactory
Anchorage against
Sliding is required
unsatisfactory
Stability check Against
SEISMIC LOAD as per
Appendix E of API 650
Anchorage Ratio
If 1.54
Mechanical
Anchorage is
required (Not self
anchored)
No
Tank is Self-
Anchored
Yes
TANK
OVERTURNING
STABILITY
1
END of
Calculations
90

6.5 2D and 3D Drawings
The arrangement of stiffeners at roof of the tank and location of stairs and some other
attachments is shown in 2D diagram. 3D modeling of storage tank that is develop with the
help of Pro E wildfire 5.0 is shown below:


Figure 45. 3D Model of storage tank


91





Figure 46. 3D Model of storage tank


92

CHAPTER # 07:
DEVELOPMENT OF STORAGE TANK DESIGN SOFTWARE &
VERIFICATION OF RESULTS USING ETANK 2000

7.1 Overview
FYP-Storage Tank Design software is developed by using Microsoft Excel Visual Basic
Programming Technique. It is comprehensive, easy-to-use software program for the design, and
evaluation of welded steel oil storage tanks according to American Petroleum Institute (API)
Standards 650. It provides owners, operators and engineering firms with quick easy and
comprehensive design for new tank construction and evaluation of existing tanks.

7.2 Design Capabilities
Steel Oil Storage Tank Design
Design Output detailed & semi detailed Reports
API 650 Standards, 10
th
edition
Allowable Fluid Height & diameter
Shell course thickness using one foot method
Up to 60 m shell height& 60 m internal diameter
Intermediate Wind girder requirements
Bottom plate + annular Plate minimum thickness evaluation
Design of Self supported cone roof
7.3 Key Features
Built for Real World Applications
Designed for fast input
Recheck of the Design input Data
Detailed and semi-detailed output Results
Just one click Design

7.4 Application Areas
Can be use to design all welded oil storage Tank that incorporates API 650 Standards.


Welded oil Storage Tank Design Software
Figure 47. Arrangement of Stiffeners at Roof
93
























7.5Visual Basic Programming for Shell Design
Figure 48 Snap shot of software
Input is fast because each input item includes an edit box
with the units displayed & Read Values provides the
rechecking of the design data input
Figure 49 Design report showing design & hydrostatic testthickness
94

The coding started with the calculation of number of shell courses. For this purpose user must
define the height of the shell and width of shell course.

n = H1 / W
Where n = number of courses required
H1 = height of shell
W = width of shell course provided
Dim MyDoubleAs Double
Dim Temp As Double

MyDouble = Int(n)
Debug.Print "MyDouble: " &MyDouble

Temp = n - MyDouble

If Temp > 0 Then
MyDouble = MyDouble + 1
End If
n = MyDouble
Dim J As Integer
J = 1
Now,
Using the formulae for design thicknesstd, hydrostatic test thickness tt, width
of each course iwand weight of each shell course wt by considering each shell
course

Dim I As Integer
95

For I = 0 To n - 1 Step 1

td(J) = ((4.9 * D * (HL1 - ((I) * W) - 0.3) * G) / Sd) + CA
tt(J) = ((4.9 * D * (HL1 - ((I) * W) - 0.3)) / St)
iw(J) = (n + 1) * W - (n) * W
Wt(J) = (3.142 * 9.81 * D * td(J) * iw(J) * Sm) / (1000000)


J = J + 1
Next I
Now the next step is to print out the calculated result into respective cells and
the code is:
Sub shelldesign22_Click()

Dim rg As Range
Set rg = ThisWorkbook.Worksheets(1).Range("B52:B65")

rg.CurrentRegion.ClearContents
Set rg = ThisWorkbook.Worksheets(1).Range("C53:F61")
Range("C53:F61").UnMerge
rg.ClearContents
Set rg = Nothing




Dim Para As String
96

Para = " SHELL DESIGN as stated by 5.6 API 650" &vbCr& _
"The minimum design shell thickness and hydrostatic test shell
thickness are calculated by" &vbCr& _
"1 foot method are given below:" &vbCr& _
"The selected / Provided shell thickness must be greater of
the values than calculated shell thickness as a factor of
safety" &vbCr& _
". "

Range("C53:F61").Merge
Range("C53:F61").Value = Para
Set rg = Nothing

' ----------------------------------
Dim I As Integer
Dim J As Integer
J = 1
Dim rg2 As Range
Set rg2 = ThisWorkbook.Worksheets(1).Range("C64")

Range("B62").Font.Size = 15
Range("B62").Font.Color = RGB(25, 25, 255)
Range("B53").Font.Size = 15
Range("B53").Font.Color = RGB(25, 25, 255)
Range("B53").Value = " SHELL DESIGN "
Range("B54").Value = " As stated by 5.6 of API 650 "
Range("B62").Value = " - DESIGN SHELL THICKNESS (td),
HYDROSTATIC TEST THICKENESS (tt),WIDTH(iw) and WEIGHT (wt) of
each uncorroded Shell are summerized as: - "
97


For I = 1 To n Step 1

' Transfer values to the worksheet

rg2.Value = "td(" & J & ")" & " = "
rg2.Offset(0, 1).Value = td(J)
rg2.Offset(0, 2).Value = "mm"

rg2.Offset(0, 3) = "tt(" & J & ")" & " = "
rg2.Offset(0, 4).Value = tt(J)
rg2.Offset(0, 5).Value = "mm"


rg2.Offset(64 + n - 62, 0).Value = "iw(" & J & ")" & " = "
rg2.Offset(64 + n - 62, 1).Value = iw(J)
rg2.Offset(64 + n - 62, 2).Value = "m"


rg2.Offset(64 + n - 62, 3).Value = "Wt(" & J & ")" & " = "
rg2.Offset(64 + n - 62, 4).Value = Wt(J)
rg2.Offset(64 + n - 62, 5).Value = "KN"




' Move down to next row
98

Set rg2 = rg2.Offset(1, 0)

J = J + 1

Next I

' Print Sum
Set rg2 = rg2.Offset(1, 0)
rg2.Offset(2 + n, 3).Value = "WEIGHT TOTAL: "
rg2.Offset(2 + n, 4).Value = Sum
rg2.Offset(2 + n, 5).Value = "KN"



' ----------------------------------



End Sub





The following output result appeared first pressing start button and then
selecting shell design as:
99





Figure50. Message Box Indicating the completion of calculation









100






Figure 51Output Result






7.6 VERIFICATION OF RESULTS
101

A large number of software is available for designing and evaluation of welded oil storage
tank as per codes and standards. E-tank 2000 is the most dedicated and extensively used
software.
In order to verify our design calculations we contacted Mr. Jeffcott Smith-CEO Etank2000,
who was kind enough to give us a student version of the software for the final year project.
Unfortunately the working of this version is quite limited and we can only verify the shell
design & hydrostatic test thickness from it.
The results are in good agreement with our developed software & our calculated results.


Figure 52Verificationthrough E-TANK Software



102

CONCLUSION
The API 650 provides extensive information for designing, erection, fabrication, inspecting
of joints, and welding procedure & welder qualifications for the above ground storage Tanks
for oil storage.
It also contains dedicated appendixes for special design parameters such as seismic design
floating roof etc. it also includes the appendixes for shop-weld storage Tanks that are built at
workshop and transferred to desired locations.
However in seismic design it does not include the structural loading requirements and criteria
for soil selection and settlement technique for which Uniform Building Code (UBC) had to
be used as a supplement material. Both of the standards deal only with the Mechanical
aspects of the design.
Thus it can be concluded that designing of storage Tank for oil storage is an extensive and
difficult task for which information from within as well outside the standards has to be used.
It is also concluded that a tank is designed for the most severe combination of the various
possible loadings.

Storage tanks carry the hydrostatic pressure by simple hoop tension. The cylindrical shell has
to carry both its own weight and the weight of the supported roof by axial stresses. Wind
loading on the tank influences the axial stress.

For open tanks, primary wind girders are required to maintain the roundness of the tank when
it is subject to wind load. Secondary wind girders are needed in tall tanks.












103

REFERENCES

[1]
API 650 standards 11
th
edition

[2]
Bob Long and Bob Garner Guide to storage tank and equipment

[3]
Mohammad A El-Reedy Ph.D. Construction management and Design of
industrial concrete and steel structures

[4]
http://kolmetz.com/pdf/EDG/ENGINEERING_DESIGN_GUIDELINE__storag
e_tank_rev_2.pdf

[5] www.etank.com

[6]
Okpala, Alexander N. and Jombo, P.P.,
Design of Diesel Storage Tank in Consonance with Requirements of American
Petroleum Institute (API) Standard 650
Industrial engineering Letters, volume II, No 04, 2012.

[7]
Esdep Lecture Note [Wg15]
www.fgg.uni-lj.si/kmk//l0100.htm

[8]
Zhi Lu
Evaluation Of Design Criteria For Storage Tanks With Frangible Roof Joints
B.S., Tianjin University, 1982
M.S., Tianjin University, 1984


[9]
Praveen K. Malhotra, Senior Res. Scientist
Factory Mutual Research, Norwood, MA, USA
Simple Procedure for Seismic Analysis of Liquid-Storage Tanks





104








APPENDIX






























105


























106

Appendix C Shell Design


107



108




109

Appendix DBottom and annular Plate Design


110




111

Appendix E Intermediate wind girder


112




113

Appendix F Roof Design

114



115



116

Appendix G Tank overturning stability
117

118

119

120

121

122

123

124

125

126

127

128

129

130

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